Self-cleaning fluid dispenser

ABSTRACT

A fluid dispenser generally includes a housing and a valving rod disposed in and movable within the housing, the valving rod including a central bore, at least one inlet for receiving a cleaning fluid composed of a solvent and a gas, and one or more outlet ports in fluid communication with the bore, wherein the outlet ports are capable of directing cleaning fluid radially outwards from the bore and against an interior surface of the dispenser to facilitate the removal of at least a portion of any fluid product or derivatives thereof that may be in adherence with such interior surface.

This application is a division of application Ser. No. 10/373,367, filedFeb. 24, 2003, now U.S. Pat. No. 6,811.059.

BACKGROUND OF THE INVENTION

The present invention pertains generally to fluid dispensers and relatedapparatus used to produce on-demand foam-in-place packaging cushionsand, more particularly, to an improved system for producing anddelivering a cleaning fluid to certain internal portions of such fluiddispensers that are particularly susceptible to occlusion due tobuild-up and/or hardening of fluid within the dispenser.

The invention finds particularly utility in the field of foam-in-placepackaging, which is a highly useful technique for on-demand protectionof packaged objects. In its most basic form, foam-in-place packagingcomprises injecting foamable compositions from a dispenser into acontainer that holds an object to be cushioned. Typically, the object iswrapped in plastic to keep it from direct contact with the rising(expanding) foam. As the foam rises, it expands into the remaining spacebetween the object and its container (e.g. a corrugated board box) thusforming a custom cushion for the object.

A common foamable composition is formed by mixing an isocyanate compoundwith a hydroxyl-containing material, such as a polyol (i.e., a compoundthat contains multiple hydroxyl groups), typically in the presence ofwater and a catalyst. The isocyanate and polyol precursors react to formpolyurethane. At the same time, the water reacts with the isocyanatecompound to produce carbon dioxide. The carbon dioxide causes thepolyurethane to expand into a foamed cellular structure, i.e., apolyurethane foam, which serves to protect the packaged object.

In other types of foam-in-place packaging, an automated device producesflexible containers, e.g., in the form of bags, from flexible, plasticfilm and dispenses a foamable composition into the containers as thecontainers are being formed. As the composition expands into a foamwithin the container, the container is sealed shut and typically droppedinto a box or carton holding the object to be cushioned. The rising foamagain tends to expand into the available space, but does so inside thecontainer. Because the containers are formed of flexible plastic, theyform individual custom foam cushions around the packaged objects.Exemplary devices for automatically producing foam-in-place cushions inthis manner are assigned to the assignee of the present invention, andare illustrated, for example, in U.S. Pat. Nos. 4,800,708, 4,854,109,5,376,219, and 6,003,288, the contents of each of which are incorporatedentirely herein by reference.

One difficulty with the foamable compositions used to make polyurethanefoam for foam-in-place packaging is that the foam precursors andresultant foam tend to have somewhat adhesive properties. As a result,the foamable composition tends to stick to objects and then hardenthereon into foam. This tendency is particularly problematic inside ofthe dispenser from which the foam precursors are ejected. As is known,the polyol and isocyanate foam precursors must be withheld from mixingwith one another until just prior to injection. In the most common typeof dispenser, the two foam precursors enter the dispenser, mix with oneanother in an internal chamber disposed within the dispenser to form afoamable composition, and then the resultant foamable composition exitsthe dispenser via a discharge port. As the dispenser operates over andover again, particularly in automated or successive fashion, foamablecomposition tends to build up in the internal mixing chamber and aroundthe discharge port of the dispenser, harden into foam, and block theproper exiting of further foamable composition. As a result, the mixingchamber and discharge port must be frequently cleaned to ensurecontinued operation of the dispenser.

Further, such dispensers generally employ a valving rod that translateslongitudinally within the mixing chamber to control the flow of the foamprecursors therethrough, i.e., between an ‘open’ position, in which theprecursors flow into and through the mixing chamber, and a ‘closed’position, in which the precursors are prevented from flowing. Suchvalving rod is in contact with the foam precursors and resultantfoamable composition, and thus must also be continually cleaned in orderto prevent the build-up of foam thereon, which would otherwise impedeand eventually prevent the further movement of the valving rod withinthe dispenser.

A solvent capable of dissolving both the foam precursors and thefoamable composition is typically used to clean the dispensers. In orderto clean the dispenser on an on-going basis without the necessity offrequent removal of the dispenser from the cushion-making device formanual cleaning and/or disassembly, solvent is generally contained in areservoir located behind the mixing chamber and/or supplied to thedischarge end of the dispenser from a separate source. Part of thevalving rod moves through the reservoir as it translates between openand closed positions to partially clean the valving rod. However, thefoam precursors and reaction products thereof gradually contaminate thesolvent in the reservoir as they are transferred thereto from thevalving rod. This requires periodic removal of the dispenser to eitherreplace it with a dispenser having fresh solvent or to disassemble thecartridge for cleaning and replacement of the solvent. Further, whileprevious techniques for supplying solvent to the discharge end of thedispenser have been somewhat effective, none has been able to deliversolvent directly against the internal surfaces of the mixing chamber anddischarge port.

As a result of the foregoing shortcomings, the effective service life ofconventional dispensers has been much shorter than would otherwise bedesired. It would therefore be desirable to extend this service life tothe greatest extent possible.

Accordingly, a need exists in the art for an improved means forcontinually and automatically cleaning dispensers used in foam-in-placepackaging.

SUMMARY OF THE INVENTION

That need is met by the present invention, which, in one aspect,provides a self-cleaning fluid dispenser, comprising:

a. a housing defining an internal chamber bounded by an interior surfacewithin the housing, the housing comprising:

-   -   (1) an inlet for receiving a fluid product into the housing and        being in fluid communication with the internal chamber, and    -   (2) a discharge port through which fluid product may exit the        housing, the discharge port being in fluid communication with        the internal chamber;

b. a valving rod disposed in the housing and being movable within theinternal chamber between an open position, in which fluid product mayflow through the internal chamber and exit the housing via the dischargeport, and a closed position, in which fluid product is substantiallyprevented from flowing through the internal chamber, the valving rodcomprising:

-   -   (1) a central bore,    -   (2) at least one inlet for receiving a cleaning fluid, the inlet        being in fluid communication with the bore, and    -   (3) one or more outlet ports in fluid communication with the        bore, the outlet ports being capable of directing cleaning fluid        radially outwards from the bore and against one or more select        portions of the interior surface bounding the internal chamber        in order to facilitate the removal of at least a portion of any        fluid product or derivatives thereof that may be in adherence        with the interior surface; and

c. a delivery system adapted to supply a cleaning fluid comprising asolvent and a gas to the valving rod inlet.

By employing a cleaning fluid comprising both a solvent and a gas anddirecting such fluid radially outwards from the central bore of thevalving rod and against the interior surface of the dispenser, includingthe interior surface of the discharge port, the dispenser provides animproved means for cleaning those areas of the dispenser that are mostprone to foam build-up and occlusion. In this manner, the effectiveservice life of the dispenser is greatly extended.

Another aspect of the invention is an apparatus for dispensing fluidinto flexible containers and enclosing the fluid within the containers,comprising:

a. a mechanism that conveys a web of film along a predetermined path oftravel, the film web comprising two juxtaposed plies of plastic filmthat define one or more partially-formed flexible containers;

b. a dispenser through which a fluid product may flow in predeterminedamounts, the dispenser positioned adjacent the travel path of the filmweb such that the dispenser can dispense fluid product into thecontainers, the dispenser comprising:

-   -   (1) a housing defining an internal chamber bounded by an        interior surface within the housing, the housing comprising:        -   (a) an inlet for receiving a fluid product into the housing            and being in fluid communication with the internal chamber,            and        -   (b) a discharge port through which fluid product may exit            the housing, the discharge port being in fluid communication            with the internal chamber;    -   (2) a valving rod disposed in the housing and being movable        within the internal chamber between an open position, in which        fluid product may flow through the internal chamber and exit the        housing via the discharge port, and a closed position, in which        fluid product is substantially prevented from flowing through        the internal chamber, the valving rod comprising        -   (a) a central bore,        -   (b) at least one inlet for receiving a cleaning fluid, the            inlet being in fluid communication with the bore, and        -   (c) one or more outlet ports in fluid communication with the            bore, the outlet ports being capable of directing cleaning            fluid radially outwards from the bore and against one or            more select portions of the interior surface bounding the            internal chamber to facilitate the removal of at least a            portion of any fluid product or derivatives thereof that may            be in adherence with the interior surface; and    -   (3) a delivery system adapted to supply a cleaning fluid        comprising a solvent and a gas to the valving rod inlet; and

C. a device for sealing the plies of plastic film together to enclosethe fluid product within the containers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective, schematic view of an apparatus and system inaccordance with the present invention in which a self-cleaning fluiddispenser introduces a foamable composition or other fluid product intoa partially-formed flexible container as the container is beingcompleted;

FIG. 2 is similar to FIG. 1, except that the container has beencompleted and severed from the film webs, thereby enclosing the foamablecomposition therein, and a cleaning fluid delivery system is supplying acleaning fluid comprising a solvent and a gas to the dispenser;

FIG. 3 is an exploded view of the dispenser shown in FIG. 1;

FIG. 4 is an elevational, cross-sectional view of a fully assembleddispenser as otherwise shown in FIG. 3, taken along lines 4—4 in FIG. 6;

FIG. 5 is similar to FIG. 4 but taken along lines 5—5 in FIG. 6; also,the valving rod is shown in the ‘open’ position (whereas FIG. 4 showsthe valving rod in the closed position);

FIG. 6 shows the discharge end of the dispenser; and

FIGS. 7–10 show various views of the mixing unit component of thedispenser as shown in FIG. 3;

FIG. 11 is an elevational view of the housing component of the dispenseras shown in FIG. 3;

FIG. 12 is a cross-sectional view of the housing shown in FIG. 11;

FIG. 13 is an elevational view of the valving rod component of thedispenser as shown in FIG. 3;

FIGS. 14–15 are cross-sectional views of the valving rod shown in FIG.13, with one view being axially offset from the other by 90°;

FIG. 16 is an elevational view of the spacer portion of the internalsolvent reservoir in the dispenser as shown in FIG. 3;

FIG. 17 is a cross-sectional view of the spacer taken along lines 17—17in FIG. 16;

FIG. 18 is an elevational view of the spacer shown in FIG. 17;

FIG. 19 is a cross-sectional, elevational view of the dispenser similarto the view shown in FIG. 5, showing the dispenser in operation with thevalving rod retracted to an open position to allow the foam precursorsto mix and flow out of the discharge port of the dispenser;

FIG. 20 is similar to FIG. 19, but shows the valving rod in the closedposition to prevent the mixing and out-flow of the foam precursors, andalso shows cleaning fluid being pumped through a central bore in thevalving rod and flowing out of outlet ports at the distal end of thevalving rod and against the internal surface of the mixing chamber;

FIG. 21 is a close-up view of the circled portion of the dispenser shownin FIG. 20;

FIG. 22 is a schematic illustration of a flow-control diagram for thecleaning fluid delivery system shown in FIGS. 1 and 2; and

FIG. 23 is similar to FIG. 15, except that a cylindrical pin is disposedin the internal bore of the valving rod.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows an apparatus 10 in accordance with the present inventionfor dispensing fluid into flexible containers and enclosing the fluidwithin the containers. Apparatus 10 comprises a mechanism generallyindicated at 12 that conveys a web of film, or in this case two webs offilm 14 and 16, along a predetermined path of travel. Conveyingmechanism 12 may include a pair of storage rollers 18 a and 18 b and apair of nip rollers 20 a and 20 b. Film webs 14 and 16 are preferablysupplied as wound rolls of film that may be supported on and unwoundfrom respective storage rollers 18 a, b. Nip rollers 20 a, b rotate inopposing directions such that, when the films webs 14, 16 are passedtherebetween, the rotation of the nip rollers cause the film webs toadvance from storage rollers 18 a, b. The nip rollers 20 a, b are madeto rotate in this manner by being mechanically or otherwise coupled to asuitable power source (not shown), e.g., an electric motor.

Film webs 14, 16 may comprise any flexible material that can bemanipulated by apparatus 10, such as, e.g., various thermoplastic orfibrous materials such as polyethylene or paper. Preferably, film webs14, 16 are flexible, thermoplastic films, and may be formed from anypolymeric material capable of being formed into a foam-in-bag cushion asdescribed herein. Non-limiting examples include polyethylenehomopolymers, such as low density polyethylene (LDPE) and high densitypolyethylene (HDPE), and polyethylene copolymers such as, e.g.,ionomers, EVA, EMA, heterogeneous (Zeigler-Natta catalyzed)ethylene/alpha-olefin copolymers, and homogeneous (metallocene,single-cite catalyzed) ethylene/alpha-olefin copolymers.Ethylene/alpha-olefin copolymers are copolymers of ethylene with one ormore comonomers selected from C₃ to C₂₀ alpha-olefins, such as 1-butene,1-pentene, 1-hexene, 1-octene, methyl pentene and the like, in which thepolymer molecules comprise long chains with relatively few side chainbranches, including linear low density polyethylene (LLDPE), linearmedium density polyethylene (LMDPE), very low density polyethylene(VLDPE), and ultra-low density polyethylene (ULDPE). Various othermaterials are also suitable such as, e.g., polypropylene homopolymer orpolypropylene copolymer (e.g., propylene/ethylene copolymer),polyesters, polystyrenes, polyamides, polycarbonates, etc. The film(s)may be monolayer or multilayer films and can be made by any knowncoextrusion process by melting the component polymer(s) and extruding orcoextruding them through one or more flat or annular dies.

The “travel path” referred to herein is the route that each film web 14,16 traverses while being conveyed through the apparatus 10. Conveyingmechanism 12, and specifically nip rollers 20 a, b, cause the film webs14, 16 to converge as two juxtaposed plies of plastic film that define apartially-formed flexible container 22.

Apparatus 10 further includes a dispenser 24 through which a fluidproduct may flow in predetermined amounts. The dispenser 24 ispositioned adjacent to (or partly in) the travel path of film webs 14,16 such that it can dispense a fluid product into the partially-formedflexible container 22. This may be accomplished by providing a manifold26 (shown in phantom for clarity) or similar device to maintaindispenser 24 in a desired position relative to the travel path of filmwebs 14, 16. Manifold 26 may also be used to facilitate the connectionto dispenser 24 of suitable piping, tubing, or other type of conduit topermit desired fluids to be transported to the dispenser. Manyconfigurations are possible. As illustrated (again, in phantom forclarity), a conduit 28 from a first fluid source, shown schematically at30, is connected to dispenser 24 via manifold 26 at first inlet 32.Similarly, a conduit 34 from a second fluid source, shown schematicallyat 36, is also connected to dispenser 24 via manifold 26 at second inlet38. Respective pumps 29 and 35, or other suitable devices for causingfluid flow, may be used to facilitate the transfer of fluid from thefirst and second fluid sources 30 and 36, through the respectiveconduits 28 and 34, and into dispenser 24.

For foam-in-place packaging, dispenser 24 is preferably adapted todispense a fluid product selected from polyols, isocyanates, andmixtures of polyols and isocyanates. Thus, first fluid source 30 maycomprise a first fluid product comprising one or more polyols and thesecond fluid source 36 may comprise a second fluid product comprisingone or more isocyanates. As will be explained in further detail below,dispenser 24 thereby mixes the polyols and isocyanates into a foamablecomposition, and dispenses the mixed fluid product/foamable composition40 into the partially-formed flexible container 22. The amount of suchfoamable fluid to be dispensed into each container 22 by dispenser 24 ispredetermined, based on, e.g., the internal volume within the container,the degree to which the fluid expands as it forms into a foam, theamount of foam that is desired to be contained in each completedcontainer/packaging cushion, etc. Such determination of thepredetermined amount of fluid to be dispensed by dispenser 24 is readilyand commonly made by those having ordinary skill in the art to whichthis invention pertains, and requires no undue experimentation.

Apparatus 10 further includes one or more devices for sealing the pliesof plastic film 14, 16 together to complete the partially-formedcontainer 22, thereby enclosing the fluid product 40 therein. Inaddition to conveying the film webs 14, 16 through apparatus 10, niprollers 20 a, b may also serve a second function of producinglongitudinal seals 42 a and 42 b on container 22. This may beaccomplished via the application of sufficient heat by the nip rollers20 a, b to the two juxtaposed film plies 14, 16 to cause thelongitudinal edges thereof to fuse together. Such a process is wellknown, e.g., as described in the above-incorporated patents. A preferredheat-sealing device is disclosed in copending patent application Ser.No. 09/760,105, entitled DEVICE FOR SEALING TWO PLIES OF FILM TOGETHER,PARTICULARLY FOR ENCLOSING A FOAMABLE COMPOSITION IN A FLEXIBLECONTAINER (Sperry et al.), and filed Jan. 12, 2001, the disclosure ofwhich is hereby incorporated herein by reference.

Alternatively, one or both of film webs 14, 16 may include strips of abonding material at the longitudinal edges of the film webs, e.g., anadhesive or cohesive material, that form the longitudinal seals 42 a, bwhen the films are pressed together by nip rolls 20 a, b.

A severing and sealing mechanism 44 may also be provided to formtransverse bottom and top seals 46 and 48, respectively, preferably bythe application of sufficient heat and pressure to cause the films tofuse together across the entire width of the film webs. In a processthat is also well described in the above-incorporated patents,transverse bottom seal 46 is first formed then, as the film webs 14, 16are advanced by nip rollers 20 a, b (and also longitudinal seals 42 a, bformed thereby), dispenser 24 dispenses fluid product 40 into thepartially-formed container 16 as the container is being formed. When asufficient, predetermined amount of fluid product 40 has been added tothe container and a sufficient amount (length) of the film webs 14, 16have been withdrawn from storage rollers 18 a, b to achieve a desiredlongitudinal length for container 16, severing and sealing mechanism 44forms top transverse seal 48 (FIG. 2) to thereby seal the containerclosed and complete the partially-formed container 16, which becomes acompleted flexible container 50, with fluid product 40 enclosed therein.

Simultaneous with or just after the formation of top transverse seal 48,severing/sealing mechanism 44 severs the completed container 50 fromfilm webs 14, 16, preferably by applying sufficient heat to the filmwebs to melt completely through them such that the completed container50 drops downwards by force of gravity from apparatus 10 as shown inFIG. 2. As clearly described in the above-referenced patents, thesevering and sealing mechanism 44 may perform both functions, i.e., boththe formation of transverse seals 46, 48 and the severing of completedcontainer 50 from the film webs 14, 16, by including at least one wire(not shown) or other electrical resistance device on one or both halvesof mechanism 44. Such wire or other device is heated sufficiently tomelt through both of the juxtaposed films 14 and 16 when the wire ispressed into contact with the films, which can be done by causing bothhalves of the mechanism 44 to converge on the films and squeeze thefilms therebetween as indicated in FIG. 2. As such convergence occurs, acurrent may be sent through the wire, causing it to heat and meltthrough film webs 14, 16, thereby severing a completed container 50 fromthe film webs. At the same time, the heat from the wire causes the filmsto weld together both below and above the wire; the weld below the wireforms the transverse top seal 48 of the completed container 50 and theweld above the wire forms a transverse bottom seal as at 46 for the nextcontainer to be formed from film webs 14, 16.

Other techniques for forming transverse seals are possible, such as,e.g., employing two or more wires on one or both halves of the mechanism44, with each wire performing a separate sealing or severing function.Exemplary foam-in-place packaging machines employing conveying, sealing,and severing mechanisms as described above are available from theassignee of this invention, Sealed Air Corporation of Saddle Brook,N.J., under the trademarks INSTAPACKER™, VERSAPACKER™, andSPEEDYPACKER™, among others.

Various alternatives to the apparatus 10 shown in FIGS. 1 and 2 may beemployed to make flexible containers. For example, instead of using twoseparate webs of film to form containers as illustrated in the drawings,containers can be prepared from a center-folded film web, with the foldproviding one of the longitudinal edges of the container. The dispenseris inserted into and positioned within the center-folded web via theopposite longitudinal edge, which is initially open before being sealedclosed downstream of the dispenser, such as is described in theabove-incorporated U.S. Pat. No. 6,003,288. A further alternative is toemploy a film web carrying a plurality of partially-formed containers,e.g., a series of partially-formed containers having one or morepre-formed heat-seals and which may be separable with pre-formedperforations. Such a film web and the method by which it is convertedinto foam-containing cushions are disclosed in copending patentapplication Ser. No. 09/759,578, entitled APPARATUS FOR DISPENSING FLUIDINTO PRE-FORMED, FLEXIBLE CONTAINERS AND ENCLOSING THE FLUID WITHIN THECONTAINERS (Sperry et al.), filed Jan. 12, 2001, the disclosure of whichis hereby incorporated herein by reference.

Regardless of the specific technique employed to form the containers,such containers may have any desired size and shape, and may be a bag,pouch, or other sealed enclosure of suitable dimensions for the intendedpackaging application.

Referring now to FIGS. 3–6, fluid dispenser 24 will be described infurther detail. Fluid dispenser 24 comprises a housing 52 and a valvingrod 54 disposed within the housing. Housing 52 preferably includes anouter casing 53, which may be constructed from stainless steel or othersuitable material that is substantially inert and impervious withrespect to the fluid product to be dispensed. The casing 53 may includea retaining flange 55 to allow dispenser 24 to be mounted in andretained by manifold 26. Alternatively, dispenser 24 and manifold 26 maybe an integral unit.

Housing 52 defines an internal chamber 56 bounded by an interior surface57 within such housing. Internal chamber 56 may be provided by mixingunit 58 as shown, as an integral or removable component of the housing52.

Housing 52 additionally includes at least one inlet for receiving afluid product into the housing, such inlet being in fluid communicationwith internal chamber 56. This may be accomplished by including incasing 53 a first inlet 32 and also second inlet 38 for receiving fluidproduct into housing 52, e.g., via respective conduits 28 and 34 asnoted above. A greater or lesser number of fluid product inlets may beemployed as desired. For instance, if a single fluid product or apre-mixed fluid product is to be dispensed, i.e., as opposed to mixingtwo fluid product components in the dispenser as presently illustrated,only a single inlet into housing 52 is necessary.

Mixing unit 58, shown more fully in FIGS. 7–10, includes fluid passages60, 62 that align with respective inlets 32, 38 so that such inlets-mayfluidly communicate with the internal chamber 56, i.e., by permittingthe passage of fluid product from each inlet 32, 38 and into theinternal chamber 56, wherein such fluids may mix together.

Preferably, valving rod 54 fits relatively tightly in mixing unit 58,e.g., the outside diameter of the valving rod is in close contact withthe inner diameter of mixing unit 58, i.e., as an ‘interference fit.’ Aclose fit between the valving rod and mixing unit is preferable inreducing the likelihood that fluid product(s) will leak from internalchamber 56 and into the other parts of housing 52 when such fluidproducts flow through the internal chamber (i.e., when the valving rodis in the ‘open position’ as shown in FIG. 19 (discussed below)).

Mixing unit 58 is preferably constructed from TEFLON (i.e.,tetrafluoroethylene (TFE) or fluorinated ethylene-propylene (FEP)polymers) or any other suitable material that is substantially inert andimpervious with respect to both the fluid product to be dispensed andthe cleaning fluid used. It is to be understood, however, that a mixingunit as herein described is not critical to the invention, but is merelyone means for providing an internal chamber through which fluid productflows and/or in which fluid product components can mix. For example,such internal chamber may instead be provided and defined by theinterior surface 64 of the casing 53.

Housing 52 further includes a discharge port through which fluid productmay exit housing 52, such discharge port being in fluid communicationwith internal chamber 56. As illustrated (FIGS. 7–12), this may beachieved by including in casing 53 a discharge port 66, which is alignedin housing 52 with a corresponding discharge port 68 of mixing unit 58.Discharge port 66 has an interior surface 59 that defines, i.e., bounds,part of the internal chamber 56 of housing 52. Interior surface 59results from the wall thickness of casing 53. Thus, the internal chamber56 is defined or bounded by both interior surface 57 (associated withmixing unit 58) and interior surface 59 (associated with discharge port66 of casing 53).

Valving rod 54 is disposed in housing 52 and is movable within internalchamber 56 between:

-   -   an open position as shown in FIG. 19, in which fluid product may        flow through the internal chamber and exit housing 52 via        discharge ports 66, 68; and    -   a closed position as shown in FIG. 20, in which fluid product is        substantially prevented from flowing through internal chamber        56.

As indicated in FIGS. 4–5, housing 52 generally has a longitudinal axis“a—a,” and valving rod 54 translates between such open and closedpositions along the longitudinal axis a—a, as indicated by the two-wayarrow. Guide rings 69, e.g., a stack of washers, may be provided inhousing 52 to assist in maintaining valving rod 54 in proper alignmentwith the longitudinal axis a—a as it translates between open and closedpositions. The guide washers 69 are preferably pressed into casing 53such that they exert a compressive force on mixing unit 58. Suchcompression helps to prevent fluid product (from fluid passages 60and/or 62) from leaking between the valving rod 54 and mixing unit 58when the valving rod is in the closed position as shown in FIG. 20.

FIGS. 1 and 19 illustrate dispenser 24 with valving rod 54 in the openposition. When the dispenser is used for foam-in-place packaging hasdescribed hereinabove, first inlet 32 may be placed in fluidcommunication with a first fluid product 70, comprising one or morepolyols, by connecting conduit 28 (from first fluid source 30) to inlet32. Similarly, second inlet 38 may be placed in fluid communication witha second fluid product 72, comprising one or more isocyanates, viaconduit 34 (from second fluid source 36). In this manner, when valvingrod 54 is in the open position as shown, the polyols and isocyanates mixtogether in internal chamber 56 to form a mixed fluid product/foamablecomposition 40, which then exits housing 52 via discharge ports 66, 68and flows into the partially-formed flexible container 22.

Valving rod 54 may be moved between the open and closed positionsthereof by any suitable mechanism, e.g., via an actuating mechanism 74as shown in FIGS. 1–2, which may include an actuator 76 and drive arm78. Actuator 76 may be powered electrically, pneumatically, orotherwise, and causes drive rod 78 to reciprocate both toward and awayfrom dispenser 24. Drive rod 78 is, in turn, mechanically connected tovalving rod 54 at proximal end 104 thereof, e.g., via suitableattachment to slot 80. In this fashion, when drive rod 78 reciprocatesaway from dispenser 24, valving rod 54 assumes the open position shownin FIGS. 1 and 19 and, conversely, when the drive rod reciprocatestoward the dispenser, the valving rod assumes the closed position shownin FIGS. 2 and 20.

As described hereinabove, as the dispenser operates over and over again,particularly in automated or successive fashion, the foamablecomposition 40 produced by mixing the first and second fluid products 70and 72 has a tendency to build up in and around the discharge port 66,harden into foam, and block the proper exiting of further foamablecomposition. The present invention provides an improved means forcleaning the discharge port to prevent such build-up, as will now bedescribed.

Referring to FIGS. 4–5 and 13–15, valving rod 54 comprises a centralbore 82; at least one inlet 84 for receiving a cleaning fluid, suchinlet 84 being in fluid communication with bore 82; and one or moreoutlet ports 86 in fluid communication with bore 82. Central bore 82 ofvalving rod 54 is preferably in substantial alignment with thelongitudinal axis a—a of housing 52 as shown.

As shown perhaps most clearly in FIGS. 20–21, outlet ports 86 arecapable of directing cleaning fluid radially outwards from bore 82 andagainst the interior surface 57 and/or interior surface 59 boundinginternal chamber 56. This has been found to greatly facilitate theremoval of at least a portion of any fluid product 70, 72, their mixture40, or derivatives thereof that may be in adherence with the interiorsurfaces 57 and 59 of dispenser 24, and thereby prevents or at leastsignificantly reduces the build-up of foam precursors and the foamproduced thereby on the internal chamber 56 and discharge ports 66, 68.This, in turn, substantially increases the service life of thedispenser, i.e., the period of effective operation before manualcleaning or replacement becomes necessary.

As perhaps best shown in FIG. 6, valving rod 54 include three outletports 86, evenly spaced about the circumference of the valving rod. Thishas been found to provide a sufficiently uniform distribution ofcleaning fluid against one or more select portions of the interiorsurfaces of the dispenser housing to effectuate the removal therefrom offluid product and derivatives thereof (this is described in greaterdetail below). A greater or lesser number of outlet ports 86 may beincluded as desired, depending upon the intended application fordispenser 24.

In operation, a suitable cleaning fluid is introduced into the bore 82of valving rod 54 via inlet 84. This may be accomplished in any suitablemanner. For example, the cleaning fluid may be introduced into bore 82directly, e.g., via a conduit from a cleaning fluid source that connectsdirectly to inlet 84, with such inlet being positioned as shown or insome other suitable position along valving rod 54, e.g., at or nearproximal end 104.

Alternatively, cleaning fluid may be supplied to the valving rod via aninternal reservoir within the dispenser. More specifically, as shown inFIGS. 3–5 and 20, housing 52 may comprise an internal reservoir in whichcleaning fluid may be contained. Such reservoir may includesubstantially all of the available volume inside of housing 52 thatextends from sealing ring 88 to sealing ring 90. Sealing rings 88, 90may be included to enclose cleaning fluid within the housing, i.e., inthe reservoir portion thereof. Thus, each ring preferably has an innerdiameter that closely matches, but is slightly larger than, the outerdiameter of valving rod 54. Ring 88 may also function to scrape fluidproduct and derivatives thereof from the outside of valving rod 54 asthe valving rod moves past ring 88 and into the open position. As analternative to a single ring, ring 90 may comprise a pair of concentrico-rings, with an inner ring in contact with valving rod 54 and the outerring in contact with the interior surface 64 of casing 53.

The available solvent reservoir volume in housing 52 may be increased byincluding in the housing a spacer 98, e.g., between sealing ring 88 andguide rings 69 as shown (see also FIGS. 16–18).

All of the internal components of housing 52 are held within casing 53at a desired level of compression by retaining ring 92 and snap ring 94.Snap ring 94 may be an expandable, outwardly biased ring that is held inplace against interior surface 64 of casing 53 by placing such ring 94into groove 96 in casing 53 (FIGS. 11–12).

A desired amount of a suitable cleaning solvent may be maintained withinthe internal reservoir defined in housing 52 between sealing rings 88,90. Further, the dispenser may be configured as shown such that aportion of valving rod 54 is movable through the internal reservoir.This may minimize or prevent fluid products and derivatives thereof frombuilding up on the portion of the valving rod that moves through boththe internal mixing chamber 58 and the reservoir. This is advantageousin that such build-up may otherwise prevent the movement of the valvingrod through the housing 52.

One means for supplying cleaning fluid to the valving rod via theinternal reservoir is to provide for fluid communication between thereservoir and the inlet 84 into central bore 82 of valving rod 54. Suchfluid communication may be achieved by configuring the valving rod andinternal reservoir such that inlet 84 resides inside of the reservoir,preferably inside of the portion defined by spacer 98, during at leastpart of the oscillation of the valving rod between its open and closedpositions. For example, as shown in FIG. 20, inlet 84 is positionedwithin spacer 98 when valving rod 54 is in the closed position.

Housing 52 may include at least one inlet port that allows a conduit tobe connected to the housing in such a manner that cleaning fluid can beintroduced into the internal reservoir and/or directly into the centralbore of the valving rod. In this manner, cleaning fluid from an externalsource may be added to the reservoir and/or valving rod as needed. Thus,casing 53 may include a solvent inlet 106 and, aligned therewith, acorresponding inlet 108 may be included in spacer 98 as shown (see,e.g., FIGS. 4–5). Further, a conduit 126 from an external cleaning fluidsource may be connected to dispenser 24 at solvent inlet 106, viamanifold 26 (see FIGS. 1–2).

A plug 102 may be included in the bore 82 at the proximal end 104 ofvalving rod 54 as shown in order to seal bore 82 at such proximal end(end 104 of the valving rod is termed “proximal” based on the positionalrelationship of such end with respect to actuating mechanism 74).

Regardless of the manner in which cleaning fluid is introduced into thevalving rod, the dispenser and dispensing apparatus of the presentinvention includes a delivery system 120 that is adapted to supply acleaning fluid comprising a solvent and a gas to the valving rod inlet84. The combination of both a solvent and a gas has been found to bemore effective, relative to the use of solvent alone, in cleaning fluidproducts and derivatives thereof from the internal chamber and dischargeport of the dispenser.

As illustrated in FIGS. 1–2, system 120 may include a pump 114, or othersuitable mechanism for causing fluid flow, which may be used tofacilitate the transfer of a suitable solvent from a solvent source 112.System 120 also includes a gas source 122, e.g., compressed gas.Alternatively, source 122 may be atmospheric air, in which case asuitable pump or compressor (not shown) is included to effect thetransfer of the air to the valving rod.

The solvent and gas may be supplied separately to the valving rod or asa mixture. If supplied as a mixture, delivery system 120 preferablyincludes means for mixing the solvent and gas together. For example, thesolvent flow from pump 114 in conduit 110 and gas flow from source 122in conduit 124 may be combined into a single conduit 126, e.g., via a“T” or “Y” connection, with solvent in conduit 110 merging into the gasflow in conduit 124, thereby forming a mixed gas/solvent flow in conduit126 as shown in FIGS. 1–2. The gas and solvent can be mixed in thissimple manner or, if desired, more elaborate mixing devices may beemployed.

Whatever mixing means is employed, the resultant cleaning fluid ispreferably a dispersion, with the solvent being in suspension within thegas stream. For example, the solvent and gas may be mixed at agas:solvent ratio ranging from about 50:1 to about 400:1, for instancebetween about 100:1 and about 300:1, such as between about 150:1 and250:1, e.g., 200:1.

Delivery system 120 may supply the cleaning fluid to the valving rod atany effective pressure to achieve an desired degree of cleaning. Suchpressure will, in turn, depend on a number of factors, such as theselected gas and solvent in the cleaning fluid, the ratio ofgas:solvent, the material to be cleaned from the dispenser, theconfiguration and dimensions of the dispenser, etc. Generally, apressure ranging form about 0.5 to about 10 psi will be effective inmany instances, particularly when the gas:solvent ratio falls within theabove values. For example, at a gas:solvent ratio of about 200:1, acleaning fluid pressure ranging from about 1 to about 5 psi, such asfrom about 2 to about 4 psi, has been found to be suitable.

As noted above, a cleaning fluid comprising both a gas and a solvent hasbeen found to be advantageous, relative to a cleaning fluid that onlyincludes a solvent. A gas/solvent cleaning fluid travels at a highervelocity and with more turbulence than a solvent-only cleaning fluid,providing increased cleaning action and energy at the dispenser tip.This not only results in increased cleaning efficacy, but it alsopermits less solvent to be used than with solvent-only systems.

Delivery system 120 may further include some means for detecting thepressure within the delivery system, such as a pressure transducer 128or other type of pressure detector/indicator, in fluid communicationwith system 120 at conduit 126 as shown. Pressure transducer 128 may beused in conjunction with a means for controlling delivery system 120based, at least in part, on the detected pressure. One such controlmeans is shown in FIG. 22, wherein a flow-control diagram for deliverysystem 120 is schematically illustrated.

Referring now to FIG. 22, solvent pump 114 delivers a predeterminedamount of solvent from solvent reservoir 112 into the delivery system120. There are many types of pumps that could be used to deliver thesolvent, such as a metering-type pump, e.g., a solenoid driven diaphragmpump, such as model 120SP pump, manufactured by Bio Chem Valve, Inc. ofBoonton, N.J. With each actuation of the solenoid, a predeterminedamount of solvent is pumped into the delivery system, e.g., 25 microliters of solvent per actuation. The pump can be actuated multiple timesduring a cleaning cycle to deliver a desired amount of solvent into thesystem. For example, the pump can be actuated 4 times during a cleaningcycle, with the resultant solvent entering the system being 100 microliters, or 1/10 of 1 milliliter. Alternatively, pumps of differingoutputs could be used to deliver the same amount of solvent; i.e. a 50micro liter pump actuated twice will deliver the same total of 100 microliters, etc.

A flow of gas is introduced into the delivery system during the cleaningcycle by gas source 122. Preferably, the gas carries a relatively smallsolvent charge through the system to fluid dispenser 24 (via conduit126). As noted above, the gas breaks the solvent charge into smalldroplets, and adds energy to the solvent's cleaning capability so that athorough flushing of the fluid dispenser is possible with a relativelysmall amount of solvent. Any suitable gas may be used. For example,atmospheric air may be used, in which case gas source 122 may be an airpump or compressor, e.g., a motor-driven diaphragm pump, such as a model1624TO12S-70 pump from Virtual Industries of Colorado Springs, Colo. Thepump or compressor may be operated for an amount of time as determinednecessary for adequate cleaning during the cleaning cycle, e.g., rangingfrom about 1 to about 20 seconds, such as from about 2.5 to about 10seconds, at an airflow ranging, e.g., from about 10 to about 1000cc/min, such as from about 50 to about 500 cc/min., or 100 to about 300cc/min, at a generated pressure ranging, e.g., from about 1 to about 20psi, e.g., from about 2 to about 10 psi, such as from about 2 to about 5psi. For example, the foregoing pump has been successfully operatedduring a series of cleaning cycles, with the pump generating an airoutput of approximately 150 cc/min at 2.8 PSI for 8 seconds whilecarrying 100 micro liters of solvent during each cleaning cycle. It isto be understood that the foregoing are merely illustrative of air andsolvent flow rates that may be selected, and that other flow rates maybe employed as deemed desired or necessary, depending upon the specificapplication of the dispenser, type of solvent, etc. Other types of airsupplies could be utilized, including different types of pumps,compressed air, etc. An alternative gas, such as nitrogen, could besupplied in a bottle and used in place of air.

The internal pressure of delivery system 120 may be monitored bypressure transducer 128. For example, a pressure transducer with adetection range of 0–5 PSI, corresponding to an output of 0 to 5 voltsD.C., such as a model ST005PG1SPCS pressure transducer manufactured byHoneywell of Acton, Mass., may be employed. However, any pressuretransducer with a range and output compatible with the delivery systemcould be used in its place. The pressure information obtained by thistransducer may advantageously be used to insure that the system has asupply of solvent, that the system is functioning correctly, etc., asdiscussed below.

The internal pressure of delivery system 120 may be controlled within adesired operating range, e.g., between 0–5 psi, by increasing ordecreasing the resistance to cleaning fluid flow as necessary to alterthe nominal operating pressure range of the system. For example, acylindrical pin 132 may be disposed within the internal bore 82 ofvalving rod 54, as shown in FIG. 23, to function as a pressurerestrictor. The diameter of pin 132 is slightly smaller than that ofbore 82. By virtue of its presence in bore 82, pin 132 adds resistanceto the flow of cleaning fluid, and thereby increases the internalpressure of the delivery system in such a way that pressure transducer128 is able to sense small pressure changes within the valving rod. Inthis manner, the pressure transducer can detect the presence of both gasand solvent in the delivery system. This may be achieved by selectingthe sizes of the central bore 82 of the valving rod and the diameter ofthe cylindrical pin 132 to create a back pressure inside the system thatis easily detectable by the pressure transducer. For example, theforegoing sizes may be chosen to create a baseline pressure ofapproximately 0.5–1 psi. The “baseline” pressure is the system pressurethat results from operating the air supply pump without operating thesolvent pump. When solvent is added to the system, its increased densitymakes it more difficult to pass through the restricted central bore 82,which increases the backpressure and raises the internal pressure of thesystem. This rise in pressure is detectable by the pressure transducer128, thereby providing an indication of the presence of solvent in thecleaning fluid flowing through the valving rod. This information, inturn, may be used to monitor and control the delivery system functions,as well as the other functions of the dispensing apparatus 10, asdiscussed below.

As will be understood by those of ordinary skill in the art, there aremultiple variables that contribute to the choice of the actual size ofthe cylindrical pin 132. Among these are the pressure and output of thechosen gas supply, the pressure loss in conduit 126, and the size of thecentral bore 82 of valving rod 54. For example, using the aforementionedair supply pump, and a central bore 82 diameter of 0.071 inch, acylindrical pin 132 diameter of 0.063 inch produces a baseline pressureof approximately 0.5–1 psi. This is merely one example, however, and theselected baseline pressure may change to accommodate applicationdifferences due to, e.g., the use of particular precursor chemicals,solvent type, etc. and will be taught to those of ordinary skill in theart by practice of the present invention.

A controller 130 may be employed to control the operation of thedelivery system 120. Such controller may be programmed to operate theair supply and solvent pump, and to analyze data from the pressuretransducer. For example, it may cause cleaning cycles to be performed asnecessary and allow operation of the fluid dispenser 24 only when thecondition of the cleaning fluid delivery system and fluid dispenser arewithin normal operating parameters. Controller 130 could be in the formof, e.g., a programmable logic controller or dedicated circuit board,and may further be included on a circuit board that controls the entiredispensing apparatus 10, thus encompassing not only the cleaning fluiddelivery system 120, but also control of dispenser 24, precursorchemicals 30 and 36, film webs 14 and 16, heat sealing devices 20 and44, etc. For purposes of simplicity and clarity, only the components ofthe delivery system 120 are illustrated in the schematic control drawingof FIG. 22.

Upon start up of the dispensing apparatus 10, controller 130 operatesthe air supply pump 122 for a period of time that allows the baselinepressure to be measured by the pressure transducer 128. If theabove-described pressure transducer is used, the output thereof is involts D.C., and ranges from 0–5 volts. Thus, if the baseline reading is1 volt, for example, the controller 130 may be programmed to set aminimum value, or hurdle that the system must reach as an indicationthat there is sufficient solvent at the valving rod. Such hurdle may be,e.g., 0.6 volts above the baseline, or, in this case, 1.6 volts.

After the baseline pressure has been established, controller 130 primessystem 120 by actuating the solvent pump 114 and monitoring the pressurespikes that result from the actuations. Each time the solvent pump isactuated, a sharp, momentary increase in system pressure is seen. Untilthere is solvent at the restriction, i.e., pin 132, in the valving rodbore 82, these pressure spikes stay below the 1.6 volt hurdle. Once thesolvent reaches the restrictor pin 132 in the valving rod, the increaseddensity of the solvent makes it more difficult to pass through thevalving rod bore, and the increased backpressure makes the pressurespikes substantially more pronounced, such that they clear the 1.6 volthurdle. To insure that the system is sufficiently primed, the controllermay further be programmed to look for multiple consecutive spikes abovethe hurdle, e.g., three such spikes.

A cleaning cycle, as illustrated and described in connection with FIG.2, follows immediately after each foam-in-place dispensing cycle, asillustrated and described in connection with FIG. 1. As soon as valvingrod 54 returns to the closed position, the air supply (i.e., air pump)122 is turned on and the solvent pump 114 is actuated. The amount ofsolvent entering the system is determined by the number of actuations ofthe solvent pump. The amount of solvent is determined by practice andmay change depending on the attributes of the particular fluid productsbeing used. With the particular system as described hereinabove, four(4) actuations per dispense cycle have been shown to be sufficient. Thisprovides a total of 100 micro liters of solvent per dispense cycle, withfour 25 micro liter bursts of solvent being introduced into the airstream generated by air pump 122. The actuations may occur at anydesired interval, e.g., ½ second intervals, but could be made faster orslower depending on preference. In this case, the needed solvent isdispensed in 2 seconds.

The air supply may continue to run as the air and solvent mixture cleansthe dispenser tip for a period of time after the solvent actuations. Thetotal cleaning cycle time may range, e.g., from about 2½ to about 10seconds, such as around 8 seconds. In practice, the gas flow rate andduration and the solvent flow rate and duration may be adjusted in orderto achieve a desired gas:solvent ratio. In the present example, anair:solvent ratio ranging from about 100:1 to about 300:1 was found tobe effective.

During the cleaning cycle, the pressure of the cleaning fluid deliverysystem 120 is monitored and a number of parameters can be determined. Asdescribed above, predetermined pressure spikes above the baselinepressure indicate whether solvent is being delivered to the valving rodbore. If the spike fails to reach the predetermined hurdle, it indicatesthat solvent is not present in the cleaning fluid, e.g., because thesolvent reservoir 112 is empty, and the controller 130 may be programmedto prevent another dispensing cycle until solvent is added. Further, ifthe supply system fails to meet its baseline pressure, it is anindication of a faulty air supply pump, a disconnected or missing supplyconduit 124 or 126, or even a missing fluid dispenser. Again, thecontroller 130 may be programmed to prevent another dispensing cycleuntil the problem is corrected. Finally, if the system pressure is toohigh, it may indicate a plugged outlet port inside the valving rod, orbetween the rod and the internal chamber of the dispenser housing, alsogenerating a fault indication in controller 130 such that correctionwould be required before the machine will operate.

FIGS. 19 and 20 illustrate in greater detail the two aforedescribedprimary modes of operation of dispenser 24, i.e.,

-   -   the dispensing cycle, wherein valving rod 54 is in the open        position as shown in FIG. 19, and    -   the cleaning cycle, wherein the valving rod is in the closed        position as shown in FIG. 20.

When the dispenser 24 is in the dispensing cycle (FIG. 19), valving rod54 retracts to the open position to allow fluid products 70 and 72 toflow through the internal chamber 56. In the process of retracting,sealing ring 88 preferably scrapes and residual solvent 100 preferablydissolves fluid product, or at least a portion thereof, from the outersurface of the valving rod, to the extent that such fluid product orderivatives thereof may be in adherence with the outer valving rodsurface, i.e., as a result of the valving rod's contact with surfaces 57and 59 of internal chamber 56. Residual solvent 100 may collect in theinternal reservoir, defined in housing 52 between sealing rings 88, 90,as the result of previous cleaning cycles, whereby some of the dispersedsolvent in the gas/solvent cleaning fluid drops out of suspension duringthe process of flowing through the reservoir and into the bore 82 of thevalving rod (via inlet 84). Generally, the level of residual solvent 100in the reservoir will be determined by the height of inlet 84 abovesealing ring 88, with excess solvent draining into bore 82 via inlet 84as residual solvent is intermittently added to the reservoir with eachcleaning cycle. In this manner, the residual solvent 100, which containstherein dissolved fluid product and derivatives thereof, is continuallyflushed with fresh solvent from cleaning fluid 134. If desired, solventmay be initially added to the reservoir, which is then graduallyreplaced by fresh residual solvent from cleaning fluid 134 as theinitial solvent gradually becomes ‘contaminated’ with dissolved fluidproduct during each dispensing cycle.

After the dispensing cycle has completed, valving rod 54 returns to theclosed position as shown in FIG. 20, thereby preventing further flow offluid products 70 and 72 through the internal chamber 56. When thevalving rod is in this position, the cleaning cycle may begin. Asdiscussed above, this is accomplished by operation of delivery system120, which supplies a cleaning fluid 134 comprising a solvent and a gas,e.g., a solvent/air dispersion, with the solvent being in suspensionwithin a stream of air. Delivery system 120 supplies the cleaning fluidthrough conduit 126, where it may travel into the internal reservoir ofdispenser 24 via inlet 106. The cleaning fluid 134 then flows throughinlet 84 and into central bore 82 of the valving rod 54, where itcontinues to flow until it exits the valving rod at outlet ports 86 toimpinge against and thereby clean the interior surfaces of the internalchamber 56.

Preferably, the outlet ports 86 of valving rod 54 are not aligned withinlet 32/fluid passage 60 or with inlet 38/fluid passage 62 in housing52. This prevents fluid products 70 and/or 72 from potentially beinginjected into the outlet ports 86 of the valving rod when such outletports move past the fluid passages 60, 62 as the valving rod moves toits open and closed positions.

As an alternative to the foregoing configuration for supplying cleaningfluid to the central bore 82 of valving rod 54, conduit 126 may beconnected directly to inlet 84 of the valving rod, with an internalreservoir either being omitted or segregated from the solvent that flowsthrough the valving rod.

As shown perhaps most clearly in FIG. 21, in conjunction with FIG. 6, abeneficial feature of the invention is that the outlet ports 86 ofvalving rod 54 are capable of directing cleaning fluid 134 radiallyoutwards from central bore 82 and against the interior surfaces 57and/or 59 bounding the internal chamber 56. As used herein, the phrase“radially outwards” refers to the direction of fluid flow out of outletports 86, as may be determined, e.g., by the orientation and shape ofthe outlet ports, such direction being at an angle that is at least 10degrees away from the direction of the longitudinal axis a-a of housing52 and towards the surfaces 57, 59 of internal chamber 56 (see also FIG.5). It has been determined that the efficacy of cleaning fluid 134 issubstantially improved by directing such fluid radially outwards fromthe central bore of the valving rod and against the interior surface(s)of the internal chamber in housing 52. Such improvement is even morepronounced when used in combination with cleaning fluid 134, whichcomprises both a gas and a solvent. That is, the solubilizing effect ofthe solvent in combination with the energy and turbulence provided bythe gas provides an effective cleaning agent, particularly when thesolvent and gas are directed radially outwards from the valving rod toimpinge against the interior surface(s) of the internal chamber 56. Theangle of solvent flow out of central bore 82 may be at least 20 degreesaway from the longitudinal axis a—a, such as, e.g., 30°, 40°, 50°, 60°,70°, 75°, or 80° from axis a—a. For example, the angle of fluid flow maybe substantially perpendicular (i.e., 90°) to longitudinal axis a—a asshown, i.e. by orienting outlet ports 86 in a substantiallyperpendicular configuration relative to axis a—a (and central bore 82).

Typically, one of the most problematic parts of dispenser 24 for foambuild-up and occlusion is the discharge port 66 and, specifically, theinterior surface 59 thereof, which also defines part of the internalmixing chamber 56. Thus, valving rod 54 is preferably adapted to directcleaning fluid 134 against the interior surface 59 of discharge port 66when the valving rod is in the closed position. As shown most clearly inFIG. 21, this may be accomplished by placing outlet ports 86 at thedistal end 116 of valving rod 54 such that the outlet ports 86 areadjacent to the interior surface 59 when the valving rod is in theclosed position. This configuration allows the solvent to flow directlyagainst the problematic surface 59 and more effectively prevent foambuild-up on such surface.

Instead or in addition, outlet ports 86 may be made to direct cleaningfluid 134 against other select portions of internal chamber 56, i.e.,against parts of interior surface 57, e.g., by positioning the outletports adjacent to one or more of such select portions during eachcleaning cycle.

In general, somewhat greater clearance is desired between the valvingrod 54 and discharge port 66 than that between the valving rod andmixing unit 58 (as discussed above). Too tight a clearance would impedethe flow of cleaning fluid out of outlet ports 86 and increase theincidence of ‘jamming’ between the distal end 116 of valving rod 54 anddischarge port 66 as the valving rod cycles between the open and closedpositions. On the other hand, too great a clearance may reduce theeffectiveness of solvent impingement on and cleaning of the interiorsurface 59 of discharge port 66. For foam-in-place packaging, theclearance between the valving rod 54 and discharge port 66 preferablyranges from about 0.001 to about 0.010 inch.

The drawings show the distal end 116 of valving rod 54 with a conicalend face 138, which is substantially flush with the frusto-conical endface 136 of casing 53 when the valving rod is in the closed position.This does not necessarily have to be the case, however. End face 138 maybe recessed into casing 53 or extended therefrom when valving rod 54 isin the closed position, i.e., such that end face 138 is not flush withcorresponding end face 136 but, instead, is spaced either inwardly oroutwardly from end face 136. For example, end face 138 could be spacedinwardly of end face 136 (i.e., into casing 53) by a distance ranging,e.g., from about 0.010 to about 0.1 inch, such as about 0.050 inch.

While the distal end 116 of valving rod 54 is shown as cone-shaped, thisis not a critical feature of the invention. Distal end 116 may have anydesired shape, e.g., flat, concave, convex, curved, angular, etc.

As a result of the cleaning cycle, a mixture 118 of dissolved fluidproduct and solvent drips from the discharge port 66, i.e., from thespace between the interior surface 59 of the discharge port and thedistal end 116 of the valving rod 54. Thus, fluid product andderivatives thereof that would otherwise occlude the discharge port 66are dissolved, the gas in the gas/solvent cleaning fluid dissipates, andthe resultant dissolved fluid product/solvent mixture drips into thenext partially-formed container to be made into a foam-in-place cushion.The amount of such fluid product/solvent mixture is quite small inrelation to the total amount of fluid product 40 that will be dispensedinto such container, particularly when employing a cleaning fluidcomprising both gas and a solvent in accordance with the presentinvention, thus having no adverse effect on the expansion/foam formationof the foamable fluid product in such container.

Any suitable solvent may be used in which the fluid products 70, 72,fluid product mixture 40, or derivatives thereof are at least partiallysoluble. “Derivatives” refers to any reaction-products (e.g.,polyurethane), residue (e.g., by evaporation), or individual componentsof the fluid product or mixture of fluid products (where two or morefluid products are mixed in the dispenser). Where the dispenser 24 isused to produce foam-in-place packaging cushions, the solvent employedis preferably capable of at least partially dissolving both the polyoland isocyanate foam precursors, as well as the foamable composition andpolyurethane foam reaction-products produced by their mixture. Suitablesolvents for this purpose may be selected from glycols, ethers, andmixtures of glycols and ethers, e.g., a mixture of tripropyleneglycol+methyl ether.

The foregoing description of preferred embodiments of the invention hasbeen presented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and modifications and variations are possible in light of theabove teachings or may be acquired from practice of the invention.

1. An apparatus for dispensing fluid into flexible containers,comprising: a. a mechanism that conveys a web of film along apredetermined path of travel, said film web comprising two juxtaposedplies of plastic film that define one or more partially-formed flexiblecontainers; b. a dispenser through which a fluid product may flow inpredetermined amounts, said dispenser positioned adjacent the travelpath of the film web such that said dispenser can dispense fluid productinto the containers, said dispenser comprising: (1) a housing definingan internal chamber bounded by an interior surface within said housing,said housing comprising: (a) an inlet for receiving a fluid product intosaid housing and being in fluid communication with said internalchamber, and (b) a discharge port through which fluid product may exitsaid housing, said discharge port being in fluid communication with saidinternal chamber; (2) a valving rod disposed in said housing and beingmovable within said internal chamber between an open position, in whichfluid product may flow through said internal chamber and exit saidhousing via said discharge port, and a closed position, in which fluidproduct is substantially prevented from flowing through said internalchamber, said valving rod comprising (a) a central bore, (b) at leastone inlet for receiving a cleaning fluid, said inlet being in fluidcommunication with said bore, and (c) one or more outlet ports in fluidcommunication with said bore, said outlet ports being capable ofdirecting cleaning fluid radially outwards from said bore and againstone or more select portions of the interior surface bounding saidinternal chamber to facilitate the removal of at least a portion of anyfluid product or derivatives thereof that may be in adherence with saidinterior surface; and (3) a delivery system adapted to supply a cleaningfluid comprising a mixture of a solvent and a gas to said valving rodinlet; and c. a device for sealing the plies of plastic film together toenclose the fluid product within the containers.
 2. The apparatus ofclaim 1, wherein said delivery system supplies the cleaning fluid tosaid valving rod at a pressure ranging from about 0.5 to about 10 psi.3. The apparatus of claim 2, wherein said delivery system furtherincludes means for detecting the pressure within said delivery system;and means for controlling said delivery system based at least in part onthe detected pressure.
 4. The apparatus of claim 1, wherein saiddelivery system includes means for mixing the solvent and gas together.5. The apparatus of claim 4, wherein said delivery system disperses thesolvent as a suspension in the gas.
 6. The apparatus of claim 4, whereinthe solvent and gas are mixed at a gas:solvent ratio ranging from about50:1 to about 400:1.
 7. The apparatus of claim 1, wherein said dischargeport of said dispenser has an interior surface that defines part of saidinternal chamber of said housing; and said valving rod is adapted todirect cleaning fluid against said interior surface of said dischargeport when said valving rod is in said closed position.
 8. The apparatusof claim 1, wherein said housing of said dispenser further comprises aninternal reservoir in which solvent may be contained, said internalreservoir being in fluid communication with said at least one inlet intosaid central bore of said valving rod.
 9. The apparatus of claim 8,wherein at least a portion of said valving rod is movable through saidinternal reservoir.
 10. The apparatus of claim 8, wherein said housingof said dispenser has at least one inlet in fluid communication withsaid internal reservoir; and said delivery system supplies cleaningfluid to said internal reservoir via said at least one inlet in saidhousing.
 11. The apparatus of claim 1, wherein: said housing inlet influid communication with said internal chamber comprises a first inletin fluid communication with a first fluid product comprising one or morepolyols; said housing comprises a second inlet in fluid communicationwith said internal chamber and with a second fluid product comprisingone or more isocyanates; and when said valving rod is in said openposition, the polyols and isocyanates are mixed in said internal chamberand dispensed into the partially-formed flexible container.
 12. Theapparatus of claim 11, wherein said solvent is selected from glycols,ethers, and mixtures of glycols and ethers.